Seamless silhouette with engineered insulation property

ABSTRACT

Certain embodiments according to the invention provide seamless insulation articles suitable for a wide variety of uses (e.g., garments, footwear, home textile articles, etc.). In accordance with certain embodiments, the seamless insulation article includes a knit base comprising a first yarn and a second yarn incorporated into a continuous web defined by the first yarn and the second yarn in a predetermined pattern to form a plurality of three-dimensional surfaces. The plurality of three-dimensional surfaces define at least two discrete regions having different contrasting insulative capacities arranged in the predetermined pattern, in which the at least two discrete regions comprise a first discrete region and a second discrete region. The first discrete region comprises a first insulative capacity, the second discrete region comprises a second insulative capacity, and the second insulative capacity is greater than the first insulative capacity.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of U.S. Provisional Application No.62/071,162 filed on Sep. 17, 2014, the entire contents of which arehereby incorporated herein by reference.

TECHNICAL FIELD

The presently-disclosed invention relates generally to insulationfabrics and more particularly to seamless insulation articles made withsuch insulation fabrics to provide insulation and moisture wicking whilepreventing chafing.

BACKGROUND

Thermally insulating textiles are commonly developed by containing airbetween the textile material and the skin and/or body of a user. Tobetter contain air between the textile material and a user's skin, thebulk and/or thickness of the textile material is often increased, asthermal insulation of the textile material is directly correlated withthe bulk or thickness of the material. To increase the bulk in a textilematerial, the textile material may undergo raising and/or napping togenerate three-dimensional fleece. The thermal insulation of the textilematerial is directly related to the total bulk of the three-dimensionalfleece surface because the higher bulk three-dimensional surfaces entrapmore air than lower bulk three-dimensional surfaces or textile articleswithout three-dimensional surfaces. Although fleece increases a textilematerial's thermal insulation, it reduces the material's watermanagement. As such, sweat remains on the skin for a long period oftime, thereby creating an uncomfortable clammy feeling for the user.

To avoid the discomfort caused by fleece against the skin but still reapthe benefits of fleece's thermal insulative properties, users frequentlylayer garments with a smooth base layer and an insulated (often fleece)mid layer. However, layering garments adds bulk and may impair awearer's range of motion. Additionally, because different body areashave different temperature sensitivities and thermoregulative abilities,layering garments makes it difficult to provide appropriate insulationlevels for all areas of the wearer's body.

Some fabric articles have attempted to offer regions having differentheat and/or vapor exchange rates in one garment, but these fabricarticles typically have numerous seams for joining together multipleareas and/or layers in the garment. As a result, these fabric articleshave high production costs and waste associated with cutting, piecework,and sewing. Moreover, seams are often prone to failure. In addition,seams can be uncomfortable and may even chafe a wearer's skin.

Therefore there at least remains a need in the art for seamlessinsulation articles that provide insulation, breathability, and moisturemanagement while preventing chafing.

BRIEF SUMMARY

One or more embodiments of the invention may address one or more of theaforementioned problems. Certain embodiments according to the inventionprovide seamless insulation articles suitable for a wide variety of uses(e.g., garments, footwear, home textile articles, etc.). In accordancewith certain embodiments, the seamless insulation article includes aknit base comprising a first yarn and a second yarn incorporated into acontinuous web defined by the first yarn and the second yarn in apredetermined pattern to form a plurality of three-dimensional surfaces.The plurality of three-dimensional surfaces, according to certainembodiments, may define at least two discrete regions having differentcontrasting insulative capacities arranged in the predetermined patternsuch that the at least two discrete regions may comprise a firstdiscrete region and a second discrete region. The first discrete regionmay comprise a first insulative capacity, the second discrete region maycomprise a second insulative capacity, and the second insulativecapacity may be greater than the first insulative capacity.

In another aspect, certain embodiments according to the inventionprovide methods for making seamless insulation articles. In accordancewith certain embodiments, the method includes combining a first yarn anda second yarn in a continuous web in a predetermined pattern andfinishing at least one surface of the continuous web to form a pluralityof three-dimensional surfaces. The plurality of three-dimensionalsurfaces, according to certain embodiments, may define at least twodiscrete regions having different contrasting insulative capacitiesarranged in the predetermined pattern such that the at least twodiscrete regions may comprise a first discrete region and a seconddiscrete region. The first discrete region may comprise a firstinsulative capacity, the second discrete region may comprise a secondinsulative capacity, and the second insulative capacity may be greaterthan the first insulative capacity.

BRIEF DESCRIPTION OF THE DRAWING(S)

The invention now will be described more fully hereinafter withreference to the accompanying drawings, in which some, but not allembodiments of the invention are shown. Indeed, this invention may beembodied in many different forms and should not be construed as limitedto the embodiments set forth herein; rather, these embodiments areprovided so that this disclosure will satisfy applicable legalrequirements. Like numbers refer to like elements throughout.

FIG. 1 illustrates a side view of a seamless insulated article accordingto an example embodiment.

FIG. 2 illustrates a top view of a seamless insulated article of theexample embodiment illustrated in FIG. 1.

FIG. 3 illustrates a side view of a seamless insulated article of theexample embodiment illustrated in FIGS. 1-2 in use according to anexample embodiment.

FIG. 4 illustrates a side view of a seamless insulated article accordingto an example embodiment.

FIG. 5 illustrates a top view of a seamless insulated article of theexample embodiment illustrated in FIG. 4.

FIGS. 6A-6G illustrate various seamless insulation articles inaccordance with example embodiments.

FIG. 7 illustrates a process flow diagram for making a seamlessinsulation article including the optional steps of designing thepredetermined pattern, laminating the seamless insulated article with asecond article, and removing the seamless insulated article from thecontinuous web according to the predetermined pattern according to anexample embodiment.

DETAILED DESCRIPTION

The invention now will be described more fully hereinafter withreference to the accompanying drawings, in which some, but not allembodiments of the invention are shown. Indeed, this invention may beembodied in many different forms and should not be construed as limitedto the embodiments set forth herein; rather, these embodiments areprovided so that this disclosure will satisfy applicable legalrequirements. As used in the specification, and in the appended claims,the singular forms “a”, “an”, “the”, include plural referents unless thecontext clearly dictates otherwise.

In accordance with certain embodiments, the invention includes seamlessinsulation articles suitable for a wide variety of uses (e.g., garments,footwear, home textile articles, etc.). Seamless insulation articles,according to certain embodiments, may include a knit base comprising afirst yarn. Such embodiments may also include a second yarn incorporatedinto a continuous web defined by the first yarn and the second yarn in apredetermined pattern to form a plurality of three-dimensional surfaces.In accordance with certain embodiments, the plurality ofthree-dimensional surfaces may define at least two discrete regionshaving different contrasting insulative capacities arranged in thepredetermined pattern such that the at least two discrete regions maycomprise a first discrete region and a second discrete region. The firstdiscrete region may comprise a first insulative capacity, the seconddiscrete region may comprise a second insulative capacity, and thesecond insulative capacity may be greater than the first insulativecapacity. In this regard, the seamless insulation article may provide,for example, a base layer that incorporates the insulative properties ofa fleece layer (e.g., a mid-fleece layer) into the base layer whilemaintaining the moisture wicking properties of a base layer andpreventing chafing. In this regard, certain embodiments provide a singlelayer material (e.g., a seamless insulation article) that may provide orcomprise the same or similar physical properties traditionally onlyrealized by the use of multiple layers (e.g., a base layer incombination with a fleece layer).

In one aspect, the invention includes seamless insulation articlessuitable for a wide variety of uses (e.g., garments, footwear, hometextile articles, etc.) that provide insulation, breathability, andmoisture management while preventing chafing. As used herein, the term“seamless” may comprise an article formed with no or in some embodimentsa minimal number of sewn seams. In accordance with certain embodiments,the articles are devoid of any sewn seams. FIG. 1 illustrates a sideview of a seamless insulated article according to an example embodiment.In accordance with certain embodiments, the seamless insulation article10 includes a knit base 1 comprising a first yarn and a second yarnincorporated into a continuous web defined by the first yarn and thesecond yarn in a predetermined pattern to form a plurality ofthree-dimensional surfaces 2. In accordance with certain embodiments andas discussed in more detail below, the plurality of three-dimensionalsurfaces may be formed by utilizing the second yarn as a floating yarn,in which the second yarn is not anchored or strongly anchored into thecontinuous web at all areas of the continuous web. In this regard, thefloating yarn (e.g., the second yarn) may be free or have a degree offreedom to generate the plurality of three-dimensional surfaces in thez-direction. The predetermined pattern may comprise three-dimensionalsurfaces of various predetermined sizes, spacings, and heights (i.e., inthe Z-direction perpendicular to the knit base). FIG. 2 illustrates atop view of a seamless insulated article of the example embodimentillustrated in FIG. 1. As shown in FIGS. 1 and 2, for example, theplurality of three-dimensional surfaces 2 may define at least twodiscrete regions 3, 6 having different contrasting insulative capacitiesarranged in the predetermined pattern such that the at least twodiscrete regions may comprise a first discrete region 6 and a seconddiscrete region 3. For example, the first discrete region 6 may comprisea first insulative capacity, the second discrete region 3 may comprise asecond insulative capacity, and the second insulative capacity may begreater than the first insulative capacity.

In accordance with certain embodiments and as illustrated by FIG. 3, forinstance, the seamless insulation article 10 may comprise an outersurface 7 and a skin surface 8. In such embodiments, for example, theouter surface 7 may comprise a smooth topography and may be positionedaway from the body of a wearer. In this regard, the outer surface 7 maybe exposed to the ambient environment or a second article (e.g., one ormore layers of material, which may provide additional insulation,moisture management, water resistance, water repellency, etc.).Moreover, the plurality of three-dimensional surfaces 2 may be disposedon the skin surface 8 facing a wearer's skin 5 and may define athree-dimensional topography. However, in other embodiments, forinstance, the skin surface 8 may comprise a smooth topography, and theouter surface 7 may comprise a three-dimensional topography such thatthe plurality of three-dimensional surfaces face the ambient environmentrather than the skin 5. In certain embodiments, the skin surface,whether it has a smooth or three-dimensional topography, may be brushed,sanded, or generally softened to enhance the comfort level by impartinga softer touch to a wearer's skin and to reduce chaffing. In addition,the first yarn and/or the second yarn may comprise filaments and/orfiber bundles that improve the moisture wicking properties of theseamless insulation article 10. In this regard, for example, the fiberbundles and/or filaments of the second yarn may contact a wearer's skin5 via the plurality of three-dimensional surfaces 2 and thereby wick andtransfer moisture from the skin 5 along the fiber bundles and/orfilaments towards the outer surface 7. In some embodiments, forinstance, the first yarn may comprise a first yarn denier, the secondyarn may comprise a second yarn denier, and the first yarn denier may befiner than the second yarn denier such that the finer yarn faces awayfrom the skin. In this regard, the differences in denier may enhance themovement of moisture (e.g., liquid sweat) from the skin to the outersurface 7, from where it will evaporate. In this regard, certainembodiments may comprise a greater amount of finer denier yarn on thesurface of the article configured to be positioned away from a wearer.As such, the moisture wicking may reduce any discomfort to the wearercaused by a clammy feeling and/or a post-exercise chilling effect as aresult of moisture retention. In this regard, for instance, certainembodiments beneficially provide targeted insulative capacity (e.g.,localized regions of increased or decreased degrees of insulation basedon the predetermined design) while simultaneously providing moisturemanagement due, for example, by the transportation of moisture (e.g.,sweat from a wearer) away from the skin of a wearer.

Furthermore, on the skin surface 8, according to certain embodiments,for example, the plurality of three-dimensional surfaces 2 may define aplurality of air channels 9 therebetween. In certain embodiments, forinstance, the plurality of air channels 9 may extend in one direction(e.g., X or Y direction), both directions (e.g., X and Y directions), orintersect each other. In this regard, the plurality of air channels 9may provide good thermal insulation in static conditions when no windand/or no to low movement of the wearer (e.g., when the wearer is in alow metabolic state) and improved air movement through the plurality ofair channels 9 and therefore better cooling, sweat evaporation, and lessheat stress when the wearer is in an active state. As such, theplurality of air channels 9 may further improve the moisturetransportation properties (e.g., evaporative cooling) of the seamlessinsulation article 10. For instance, the air channels may provide thearticle a structure in which the movement of air through the airchannels facilitates or promotes transportation of moisture (e.g., sweatfrom a wearer) away from the skin of a wearer by, for example, moistureconcentration gradients created or present between the wet or moist skinsurface and the relatively less moist air travelling through the airchannels. Such a transfer of moisture away from the skin of a wearer maynot only reduce any clammy feeling realized by the wearer due tounwanted sweat retention, but may also provide the additional benefit ofproviding a cooling effect to the wearer (e.g., evaporative cooling).Accordingly, certain embodiments may provide a desirable combination oflocalized or targeted insulative capacities; moisture management (e.g.,moisture transportation away from the skin of a wearer by wicking and/ormass transport driven movement of moisture); and a cooling effect (e.g.,evaporative cooling).

As noted above, certain embodiments may comprise a plurality ofthree-dimensional surfaces formed by utilizing the second yarn as, forexample, a floating yarn, in which the second yarn is not anchored orstrongly anchored into the continuous web at all areas of the continuousweb. For instance, the floating yarn (e.g., the second yarn) may be freeor loosely stitched into the continuous web at regions of locationassociated with the three-dimensional surfaces while the floating yarn(e.g., the second yarn) may be anchored to the continuous web and/orfirst yarn at regions associated, for example, with the air channels 9illustrated in FIG. 3. In this regard, the floating yarn (e.g., thesecond yarn) may generally free to move relative to the first yarn(e.g., to generate the plurality of three-dimensional surfaces in thez-direction) at regions associated with the three-dimensional surfaceswhile being secured to the first yarn at regions associated with the airchannels.

According to certain embodiments, for instance, the plurality ofthree-dimensional surfaces may comprise at least a first group ofthree-dimensional surfaces 2 and a second group of three-dimensionalsurfaces 4. In such embodiments and as shown in FIGS. 4 and 5, forexample, the first discrete region 6 of the seamless insulation article20 may comprise the first group of three-dimensional surfaces 2, and thesecond discrete region 3 may comprise the second group ofthree-dimensional surfaces 4. However, in certain embodiments, forinstance, the first discrete region 6 may not contain anythree-dimensional surfaces. In some embodiments, for instance, thesecond group of three-dimensional surfaces may comprise a height fromabout 1 mm to about 20 mm. In other embodiments, for example, the secondgroup of three-dimensional surfaces may comprise a height from about 1mm to about 10 mm. In further embodiments, for instance, the secondgroup of three-dimensional surfaces may comprise a height from about 3mm to about 7 mm. As such, in certain embodiments, the second group ofthree-dimensional surfaces may comprise a height from at least about anyof the following: 1, 1.5, 2, 2.5, and 3 mm and/or at most about 20, 18,16, 14, 12, 10, 9, 8, and 7 mm (e.g., about 2.5-18 mm, about 3-10 mm,etc.). In certain embodiments, for example, the second group ofthree-dimensional surfaces may be taller than the first group ofthree-dimensional surfaces. In this regard, the first group ofthree-dimensional surfaces, while being shorter or smaller, according tocertain embodiments may comprise a height from at least about any of thefollowing: 1, 1.5, 2, 2.5, and 3 mm and/or at most about 19, 18, 16, 14,12, 10, 9, 8, and 7 mm (e.g., about 2.5-18 mm, about 3-10 mm, etc.). Inaddition or alternatively to, the first and second groups ofthree-dimensional surfaces may comprise the same height, but comprisedifferent areas of size. For example, the first group ofthree-dimensional surfaces may comprise the same height as the secondgroup of three-dimensional surfaces, but the individual area of one ormore (e.g., all) of the second group of three-dimensional surfaces maybe larger than the individual area of one or more (e.g., all) of thefirst group of three-dimensional surfaces. In this regard, the seconddiscrete region may comprise a larger percentage of area comprising athree-dimensional surface (e.g., bubble formation(s)) therein to providea greater insulative capacity as compared to the first discrete region.In certain embodiments, the respective heights of the first and secondgroup of three-dimensional surfaces may be the same or different (asdiscussed above), but the population density to the respectivethree-dimensional surfaces may be different to provide contrastinginsulative capacities. For example, the first and second group ofthree-dimensional surfaces may (or may not) comprise the same shape(e.g., height, individual bubble area, etc.), but the second discreteregion may comprise a greater number of individual three-dimensionalsurfaces per unit area of the article to provide insulative capacitygreater than the insulative capacity of the first discrete region.

According to certain embodiments, for instance, the predeterminedpattern may correspond to selected body region insulative requirements.As such, the seamless insulated article may comprise at least one ofinsulative portions, non-insulative portions, open mesh portions, or anycombination thereof. In this regard, for example, each of the firstdiscrete region and the second discrete region may correspond to atleast one of a spinal cord area, spine, back area, an upper back area, alower back area, a neck area, a knee back area, a chest front area, abreast area, an abdominal area, an armpit area, an arm area, an elbowfront area, a sacrum dimple area, a groin area, a thigh area, a shinarea, or any combination thereof. By way of example only, an arm area(e.g., elbow or shoulder) may have greater insulative requirements thanan armpit area, and, as such, the arm area (e.g., elbow or shoulder) maycomprise an insulative portion of a seamless insulation article to keepthe arm warm while an armpit area may comprise an open mesh portion ofthe seamless insulation article to promote ventilation in an area thatproduces more sweat than other body areas.

For example, FIGS. 6A-6G illustrate various seamless insulation articlesin accordance with example embodiments. For instance, in someembodiments and as shown in FIGS. 6A-6B, the seamless insulation article30 may comprise a seamless insulation shirt. For example, according tocertain embodiments and as shown by comparing FIGS. 6A and 6B, the frontside of the seamless insulation shirt (as shown in FIG. 6A) may have adifferent three-dimensional surface pattern than the back side of theseamless insulation shirt (as shown in FIG. 6B). In this regard, theseamless insulation shirt may have different insulation on the chestside from the back and/or shoulder regions, based at least in part ofthe chest side having a different pattern of three-dimensional surfacesthan the back side of the shirt. In addition, the seamless insulationshirt may be loose fitting or tight fitting. Moreover, in otherembodiments and as shown in FIG. 6C, for example, the seamlessinsulation article 40 may comprise a seamless insulation glove. Infurther embodiments and as shown in FIG. 6D, for instance, the seamlessinsulation article 50 may comprise a seamless insulation jacket. Inother embodiments and as shown in FIG. 6E, for example, the seamlessinsulation article 60 may comprise a seamless insulation sock. Infurther embodiments and as shown in FIG. 6F, for instance, the seamlessinsulation article 70 may comprise a seamless insulation shoe. In thisregard, seamless insulation articles according to certain embodimentsmay comprise an article or footwear in which the inner and outersurfaces can independently be tailored to match the required insulationas desired. In some embodiments and as shown in FIG. 6G, for example,the seamless insulation article 80 may comprise seamless insulationpants.

In accordance with certain embodiments, for instance, the plurality ofthree-dimensional surfaces may comprise at least one of a bubble, apile, a pillar, or any combination thereof. In further embodiments, forexample, the plurality of three-dimensional surfaces may comprise atleast one of a circular bubble, an elliptical bubble, a square bubble, arectangular bubble, irregularly shaped bubble, or any combinationthereof. As such, in some embodiments, for instance, the plurality ofthree-dimensional surfaces may comprise a three-dimensional domed shapefrom the side and any suitable geometry including, but not limited to, acircle, an ellipse, a square, a rectangle and/or the like when viewedfrom above the seamless insulation article. Moreover, for example, theplurality of three-dimensional surfaces may comprise a combination ofdifferent geometries when viewed from above the seamless insulationarticle. In this regard, the geometries of the plurality ofthree-dimensional surfaces may be tailored to fit the insulative needsof a particular application or localized region of the seamlessinsulation article.

In accordance with certain embodiments, for instance, each of the firstyarn and the second yarn may comprise at least one of a multifilamentyarn, a spun fiber yarn, a monofilament yarn, or any combinationthereof. In some embodiments, for example, each of the first yarn andthe second yarn may comprise at least one of a synthetic yarn and/orfiber, a natural yarn and/or fiber, a regenerated yarn and/or fiber,yarns and/or fibers generated from natural products, or any combinationthereof. In certain embodiments, for instance, synthetic yarns and/orfibers may comprise (but are not limited to) nylon yarns and/or fibers,acrylic yarns and/or fibers, polyester yarns and/or fibers, andpolypropylene yarns and/or fibers. In further embodiments, for example,yarns having a natural source may be obtained from cotton, wool, flax,jute, bamboo, hemp, alpaca and/or the like. In certain embodiments, byway of example only, regenerated fibers may comprise rayon. In someembodiments, for instance, yarns derived from and/or manufactured from anatural source may be obtained from soy protein, corn, and the like.According to certain embodiments, for example, yarns having filament mayhave either a flat or textured form. For example, the yarns may comprisecontinuous flat filaments, continuous textured filaments, spun yarnscomprising synthetic staple fibers and/or the like. Examples of suchfilament forms of yarn may include, but are not limited to, nylon,polyester, polypropylene and/or the like. The various yarns describedherein, for instance, may be used individually or in combination witheach other. In some exemplary embodiments, for example, the first yarnand the second yarn may comprise the same color or different colors andmay comprise different dyeability. By way of example only, in suchembodiments, the first yarn may comprise, for example, nylon, while thesecond yarn may comprise a cationic dyeable polyester. Further, the yarncombinations may be formed, for example, in the knitting process or in aseparate process prior to the knitting process.

According to certain embodiments, for instance, the seamless insulationarticle may further comprise an elastomeric yarn. In some embodiments,for example, the elastomeric yarn may comprise at least one of rubber,spandex or other elastic material such as Lycra® fiber. In certainembodiments, for instance, the elastomeric yarn may be incorporated intothe seamless insulation article by being laid-in, knit-in and/or thelike. Moreover, in some embodiments, for example, the elastomeric yarnmay comprise bare spandex laid-in or plaited with the knit base and/orsecond yarn. In further embodiments, for instance, the spandex and/orrubber may be commingled with other fibers (e.g., nylon, polyester,polypropylene, etc.) to form a synthetic filament yarn. In otherembodiments, for example, the spandex and/or rubber may be covered by atleast one of filament yarn, spun yarn (e.g., natural fibers like cotton,wool, etc. or a blend of natural fibers with synthetic fibers such as apolyester/cotton blend) and/or the like. In further embodiments, forinstance, the elastomeric yarn may further comprise a covering of flatand/or textured filament yarns such as nylon, polyester orpolypropylene. According to certain embodiments, for example, theelastomeric yarn may be utilized to form the plurality ofthree-dimensional surfaces.

In accordance with certain embodiments, for example, the seamlessinsulation article may further comprise at least one smart yarn. In suchembodiments, for instance, the at least one smart yarn may comprise atleast two polymers having different relative shrinkages when exposed toheat (e.g., dry and/or wet heat during, for example, steaming ordyeing). In certain embodiments, the three-dimensional surfaces may beformed by exploiting the different relative shrinkages. For instance,the differential shrinkage between the two polymers when exposed to heatmay enhance the three-dimensional configuration generated by the knitstructure containing, for example only, spandex. In further embodiments,for example, the at least one smart yarn may further comprise at leastone of a ceramic (e.g., zirconium carbide), a synthetic material, aphase change material (e.g., phase change polymer), a biomimetricmaterial, or any combination thereof.

According to certain embodiments, for instance, the seamless insulationarticle may further comprise at least one of a softener, anantimicrobial treatment, a wicking treatment, a soil release treatment,a water repellent, an oil repellent, a fire retardant, or anycombination thereof. In this regard, in example embodiments, forinstance, odor may be reduced in the seamless insulation article viatreatment with at least one durable antimicrobial. Further exemplaryembodiments may utilize a wicking treatment in order to increase thesurface tension of the seamless insulated article in order to betterenable moisture (e.g., liquid sweat) to move in between yarn filamentsand/or fiber bundles. In addition, some example embodiments, forinstance, may incorporate a soil release treatment into the seamlessinsulated article in order to facilitate stain removal. Moreover, inregard to softeners, for example, the skin surface of the seamlessinsulation article may be softened by at least one of a softener ormechanical softening (e.g., sanding, brushing and/or the like). Inexample embodiments utilizing mechanical softening, for instance,mechanical softening may be performed on the seamless insulation articleas a finishing process and/or on the second yarn prior to knitting.

Thus, the invention includes seamless insulation articles suitable for awide variety of uses (e.g., garments, footwear, home textile articles,etc.). In accordance with certain embodiments, the seamless insulationarticle may include a knit base comprising a first yarn and a secondyarn incorporated into a continuous web defined by the first yarn andthe second yarn in a predetermined pattern to form a plurality ofthree-dimensional surfaces. The plurality of three-dimensional surfacesmay define at least two discrete regions having different contrastinginsulative capacities arranged in the predetermined pattern such thatthe at least two discrete regions may comprise a first discrete regionand a second discrete region. The first discrete region may comprise afirst insulative capacity, the second discrete region may comprise asecond insulative capacity, and the second insulative capacity may begreater than the first insulative capacity.

In another aspect, certain embodiments of the invention provide a methodfor making a seamless insulation article. In accordance with certainembodiments, the method includes combining a first yarn and a secondyarn in a continuous web in a predetermined pattern and finishing atleast one surface of the continuous web to form a plurality ofthree-dimensional surfaces. The plurality of three-dimensional surfaces,for example, may define at least two discrete regions having differentcontrasting insulative capacities arranged in the predetermined patternsuch that the at least two discrete regions may comprise a firstdiscrete region and a second discrete region. For instance, the firstdiscrete region may comprise a first insulative capacity, the seconddiscrete region may comprise a second insulative capacity, and thesecond insulative capacity may be greater than the first insulativecapacity.

FIG. 7, for example, illustrates a process flow diagram for making aseamless insulation article according to an example embodiment. As shownin FIG. 7, the method may include an initial optional step of designingthe predetermined pattern at operation 110. Next, the method may proceedby combining a first yarn and a second yarn in a continuous web in apredetermined pattern at operation 120 and finishing at least onesurface of the continuous web to form a plurality of three-dimensionalsurfaces at operation 130. Then, the method may include the optionalsteps of combining (e.g., laminating, stitching, etc.) the seamlessinsulated article with a second article at operation 140 and removingthe seamless insulated article from the continuous web according to thepredetermined pattern at operation 150.

According to certain embodiments, for instance, combining a first yarnand a second yarn in a continuous web in a predetermined pattern maycomprise at least one of tubular circular knitting, plaiting, reverseplaiting, warp knitting, weaving, or any combination thereof. In furtherembodiments, for example, combining a first yarn and a second yarn in acontinuous web in a predetermined pattern may comprise at least one oftubular circular knitting and warp knitting on a whole seamlesssilhouette machine (e.g., Santoni® seamless knitting machine, ShimaSeiki® knitting machine, etc.). In other embodiments, for instance, thesecond yarn may be plaited with the first yarn. In this regard, in someembodiments, for example, loosely plaiting the second yarn with thefirst yarn may form the plurality of three-dimensional surfaces. Infurther embodiments, for example, the first yarn and the second yarn maybe combined via regular plaiting, and one surface of the continuous webmay be finished to form a single face fleece. In other embodiments, forinstance, the first yarn and the second yarn may be combined via reverseplaiting, and both surfaces of the continuous web may be finished toform a double face fleece. By way of example only, combining a firstyarn and a second yarn in a continuous web in a predetermined patternmay comprise forming loop yarn to a first pile height in a firstdiscrete region and forming loop yarn to a second pile height in asecond discrete region such that the second pile height is greater thanthe first pile height. In some embodiments, for instance, forming loopyarn to a first pile height may comprise forming loop yarn with no pile.

In other exemplary embodiments, however, forming loop yarn to a firstpile height may comprise forming loop yarn to a low pile height using,by way of example only, shrinkable yarn. In such embodiments, forexample, the first yarn may comprise a first shrinkage and the secondyarn may comprise a second shrinkage being different from the firstshrinkage to define a differential relative shrinkage between the firstyarn and the second yarn when exposed to heat. In certain embodiments,the three-dimensional surfaces may be formed by exploiting thedifferential relative shrinkages. By way of example only, yarnsaccording to example embodiments may comprise bicomponent polymer yarns.In such embodiments, for instance, there may be a differential relativeshrinkage between flat polyester filament yarns and textured polyesterfilament yarns. In other embodiments, for example, there may be adifferential relative shrinkage between a heat set textured polyesterfilament yarn and a non-heat set textured polyester filament yarn. Infurther embodiments, for instance, there may be a differential relativeshrinkage between a high heat set textured polyester filament yarn and alow heat set textured polyester filament yarn. Moreover, polyesterfilament yarns having different deniers may also exhibit a differentialrelative shrinkage.

According to certain embodiments, for example, combining a first yarnand a second yarn in a continuous web in a predetermined pattern mayfurther comprise incorporating at least one smart yarn into thecontinuous web. By way of example only, the at least one smart yarn maybe incorporated into the continuous web in the first discrete region inwhich the loop yarn is formed to the first pile height and/or the seconddiscrete region in which the loop yarn is formed to the second pileheight. In some example embodiments, for instance, the at least onesmart yarn may be utilized as stitch yarns in the second discrete regionin which the loop yarn is formed to the second pile height. Moreover, infurther embodiments, for example, the at least one smart yarn may beincorporated into the continuous web as a floating yarn in the firstdiscrete region in which the loop yarn is formed to the first pileheight. In such embodiments, for instance, the floating yarn is anchoredto the continuous web in the segments between the three-dimensionalsurfaces that define the plurality of air channels. In certainembodiments and as previously discussed, for instance, the at least onesmart yarn may comprise at least one of a ceramic (e.g., zirconiumcarbide), a synthetic material, a phase change material (e.g., phasechange polymer), a biomimetric material, or any combination thereof. Infurther embodiments, for example, an elastomeric material may beincorporated (e.g., plaited, commingled, warp knitted, etc.) into thecontinuous web.

In accordance with certain embodiments, for example, the method mayfurther comprise designing the predetermined pattern, combining (e.g.,laminating, stitching, etc.) the seamless insulated article with asecond article, and removing the seamless insulated article from thecontinuous web according to the predetermined pattern. In someembodiments, for instance, designing the predetermined pattern maycomprise designing the predetermined pattern for use in at least one ofa jacket, a shirt, a pair of pants, a pair of shorts, a glove, a mitt, asock, a shoe, a shoe insert, a blanket, a mattress cover, a mattressticking, or any combination thereof. In some example embodiments, forinstance, laminating (or otherwise attaching or combining) the seamlessinsulated article with a second article may comprise laminating (orotherwise attaching or combining) the seamless insulated article with acomplementary seamless article having a complementary pattern ofthree-dimensional surfaces or other non-seamless article if so desired.In such embodiments, for instance, in order to laminate the seamlessinsulated article with a complementary seamless article (or non-seamlessarticle if so desired), a tubular seamless knit may be slit so as tolaminate the open width of the seamless article. For example, the secondarticle may comprise a controlled air permeability element (e.g., awindbreaker, jacket and/or the like). In further embodiments, forexample, removing the seamless insulated article from the continuous webaccording to the predetermined pattern may comprise cutting the seamlessinsulated article out of the continuous web based on the pattern of theplurality of three-dimensional surfaces. For example, a seamlessinsulated article having a predetermined pattern of the plurality ofthree-dimensional surfaces appropriate for a seamless insulated jacketmay be cut from the continuous web to isolate the seamless insulatedjacket.

In accordance with certain embodiments, for instance, the method may bedirected to forming a seamless insulation article system. In suchembodiments, for example, the method may comprise forming a firstseamless insulation article, forming at least one additional article(e.g., an additional insulation article), and overlying the firstseamless insulation article with the at least one additional article(e.g., an additional insulation article). In this regard, the seamlessinsulation article system may provide a system comprising thin layersthat provide, for example, insulation, breathability, and moisturemanagement while preventing chafing. In this regard, certain embodimentsmay comprise a single layer article or a multi-layered article.

Although exemplary knitting processes have been described herein, one ofordinary skill in the art should understand that this disclosure is notlimited to such knitting processes. In fact, any knitting processsuitable for producing the seamless insulation article described hereinas understood by one of ordinary skill in the art may be used. Moreover,all disclosures regarding the seamless insulation article are herebyincorporated into the method disclosures discussed herein.

In this regard, the seamless insulation article may allow a user to keepselected regions of the body warm, while allowing other regions of thebody to be cooled by evaporation and/or ventilation. By way of exampleonly, selected regions such as the arms or lower back may be made tohave higher insulative capacity to keep athletes warm. In someembodiments, for example, either the right arm or the left arm may bemore insulating in order to keep the throwing arm of a pitcher warmwhile allowing the rest of the body to be cool. Moreover, the formationof the seamless insulation article as complementary single layerelements may reduce cutting and sewing costs and fabric wastage, andutilizing a seamless insulation article reduces potential failure pointsand also may reduce chafing on the user's skin. Extremely intricatepatterns of varying thickness may be achieved and used to createinfinitely varied regions of insulating warmth, range of motion, andbreathability in the fabric that may be customized for any number ofphysical activities.

In addition, similar advantages may be provided by seamless insulationarticles in the form of home textile articles, such as bed sheets andmattress covers utilized in, for example, furniture for home,institutional, and commercial markets, including transportation seating.For example, home textile articles may be configured to provide discreteregions of insulation performance in a pattern corresponding toinsulation requirements of a user's body. By way of example only,seamless insulation articles utilized as mattress covers may beconfigured to provide discrete regions offering improved breathability,ventilation, and reduced sweat for different regions of a user's body(e.g., the user's back). As such, the seamless insulation articlesdisclosed herein may provide insulation, breathability, and moisturemanagement while preventing chafing in a variety of applicationsincluding, but not limited to, garments, home textile articles and/orthe like.

Non-Limiting Exemplary Embodiments

Having described various aspects and embodiments of the inventionherein, further specific embodiments of the invention include those setforth in the following paragraphs.

Certain embodiments according to the invention provide seamlessinsulation articles suitable for a wide variety of uses (e.g., garments,footwear, home textile articles, etc.). In accordance with certainembodiments, the seamless insulation article includes a knit basecomprising a first yarn and a second yarn incorporated into a continuousweb defined by the first yarn and the second yarn in a predeterminedpattern to form a plurality of three-dimensional surfaces. The pluralityof three-dimensional surfaces define at least two discrete regionshaving different contrasting insulative capacities arranged in thepredetermined pattern, said at least two discrete regions comprising afirst discrete region and a second discrete region. The first discreteregion comprises a first insulative capacity, the second discrete regioncomprises a second insulative capacity, and the second insulativecapacity is greater than the first insulative capacity.

In accordance with certain embodiments, the plurality ofthree-dimensional surfaces defines a plurality of air channelstherebetween. Moreover, in some embodiments, the seamless insulationarticle comprises an outer surface and a skin surface, the outer surfacecomprises a smooth topography, and the plurality of three-dimensionalsurfaces is disposed on the skin surface and defines a three-dimensionaltopography. In certain embodiments, the plurality of three-dimensionalsurfaces comprises at least a first group of three-dimensional surfacesand a second group of three-dimensional surfaces, the second group ofthree-dimensional surfaces comprises a height from about 1 mm to about20 mm, and the second group of three-dimensional surfaces is taller thanthe first group of three-dimensional surfaces. In such embodiments, thefirst discrete region comprises the first group of three-dimensionalsurfaces, and the second discrete region comprises the second group ofthree-dimensional surfaces. In some embodiments, the plurality ofthree-dimensional surfaces comprises at least one of a bubble, a pile, apillar, or any combination thereof. In further embodiments, theplurality of three-dimensional surfaces comprises at least one of acircular bubble, an elliptical bubble, a square bubble, a rectangularbubble, or any combination thereof.

According to certain embodiments, the predetermined pattern correspondsto selected body region insulative requirements. In this regard, each ofthe first discrete region and the second discrete region correspond toat least one of a spinal cord area, back area, an upper back area, alower back area, a neck area, a knee back area, a chest front area, abreast area, an abdominal area, an armpit area, an arm area, an elbowfront area, a sacrum dimple area, a groin area, a thigh area, a shinarea, or any combination thereof.

In accordance with certain embodiments, each of the first yarn and thesecond yarn comprise at least one of a synthetic fiber, a natural fiber,a regenerated fiber, or any combination thereof. In some embodiments,each of the first yarn and the second yarn comprise at least one of amultifilament yarn, a spun fiber yarn, a monofilament yarn, or anycombination thereof. In other embodiments, the seamless insulationarticle further comprises an elastomeric yarn. In some embodiments, thefirst yarn comprises a first shrinkage and the second yarn comprises asecond shrinkage being different from the first shrinkage to define adifferential relative shrinkage between the first yarn and the secondyarn when exposed to heat. In further embodiments, the seamlessinsulation article further comprises at least one smart yarn, whereinthe at least one smart yarn comprises at least one of a ceramic, asynthetic material, a phase change material, a biomimetric material, orany combination thereof. In further embodiments, the seamless insulationarticle further comprises at least one of a softener, an antimicrobialtreatment, a wicking treatment, a soil release treatment, a waterrepellent, an oil repellent, a fire retardant, or any combinationthereof.

In another aspect, certain embodiments according to the inventionprovide methods for making seamless insulation articles. In accordancewith certain embodiments, the method includes combining a first yarn anda second yarn in a continuous web in a predetermined pattern andfinishing at least one surface of the continuous web to form a pluralityof three-dimensional surfaces. The plurality of three-dimensionalsurfaces define at least two discrete regions having differentcontrasting insulative capacities arranged in the predetermined pattern,said at least two discrete regions comprising a first discrete regionand a second discrete region. The first discrete region comprises afirst insulative capacity, the second discrete region comprises a secondinsulative capacity, and the second insulative capacity is greater thanthe first insulative capacity. In some embodiments, combining a firstyarn and a second yarn in a continuous web in a predetermined patterncomprises at least one of tubular circular knitting, plaiting, reverseplaiting, warp knitting, weaving, or any combination thereof. Accordingto certain embodiments, combining a first yarn and a second yarn in acontinuous web in a predetermined pattern further comprisesincorporating at least one smart yarn into the continuous web, said atleast one smart yarn comprising at least one of a ceramic, a syntheticmaterial, a phase change material, a biomimetric material, or anycombination thereof. In further embodiments, the method furthercomprises designing the predetermined pattern, laminating the seamlessinsulated article with a second article, and removing the seamlessinsulated article from the continuous web according to the predeterminedpattern. In some embodiments, designing the predetermined patterncomprises designing the predetermined pattern for use in at least one ofa jacket, a shirt, a pair of pants, a pair of shorts, a glove, a mitt, asock, a shoe, a shoe insert, a blanket, a mattress cover, a mattressticking, or any combination thereof.

These and other modifications and variations to the invention may bepracticed by those of ordinary skill in the art without departing fromthe spirit and scope of the invention, which is more particularly setforth in the appended claims. In addition, it should be understood thataspects of the various embodiments may be interchanged in whole or inpart. Furthermore, those of ordinary skill in the art will appreciatethat the foregoing description is by way of example only, and it is notintended to limit the invention as further described in such appendedclaims. Therefore, the spirit and scope of the appended claims shouldnot be limited to the exemplary description of the versions containedherein.

That which is claimed:
 1. A seamless insulation article, comprising: aknit base comprising a first yarn; and a second yarn incorporated into acontinuous web defined by the first yarn and the second yarn in apredetermined pattern to form a plurality of three-dimensional surfaces,wherein the plurality of three-dimensional surfaces defines at least twodiscrete regions having different contrasting insulative capacitiesarranged in the predetermined pattern, said at least two discreteregions comprising a first discrete region and a second discrete region,and wherein the first discrete region comprises a first insulativecapacity, the second discrete region comprises a second insulativecapacity, and the second insulative capacity is greater than the firstinsulative capacity.
 2. The seamless insulation article according toclaim 1, wherein the plurality of three-dimensional surfaces defines aplurality of air channels therebetween.
 3. The seamless insulationarticle according to claim 1, wherein the seamless insulation articlecomprises an outer surface and a skin surface, the outer surfacecomprises a smooth topography, and the plurality of three-dimensionalsurfaces is disposed on the skin surface and defines a three-dimensionaltopography.
 4. The seamless insulation article according to claim 1,wherein the plurality of three-dimensional surfaces comprises at least afirst group of three-dimensional surfaces and a second group ofthree-dimensional surfaces, the second group of three-dimensionalsurfaces comprises a height from about 1 mm to about 20 mm, and thesecond group of three-dimensional surfaces is taller than the firstgroup of three-dimensional surfaces.
 5. The seamless insulation articleaccording to claim 4, wherein the first discrete region comprises thefirst group of three-dimensional surfaces, and the second discreteregion comprises the second group of three-dimensional surfaces.
 6. Theseamless insulation article according to claim 1, wherein the pluralityof three-dimensional surfaces comprises at least one of a bubble, apile, a pillar, or any combination thereof.
 7. The seamless insulationarticle according to claim 1, wherein the plurality of three-dimensionalsurfaces comprises at least one of a circular bubble, an ellipticalbubble, a square bubble, a rectangular bubble, irregularly-shapedbubble, or any combination thereof.
 8. The seamless insulation articleaccording to claim 1, wherein the predetermined pattern corresponds toselected body region insulative requirements.
 9. The seamless insulationarticle according to claim 1, wherein each of the first discrete regionand the second discrete region correspond to at least one of a spinalcord area, back area, an upper back area, a lower back area, a neckarea, a knee back area, a chest front area, a breast area, an abdominalarea, an armpit area, an arm area, an elbow front area, a sacrum dimplearea, a groin area, a thigh area, a shin area, or any combinationthereof.
 10. The seamless insulation article according to claim 1,wherein each of the first yarn and the second yarn comprise at least oneof a synthetic fiber, a natural fiber, a regenerated fiber, or anycombination thereof.
 11. The seamless insulation article according toclaim 1, wherein each of the first yarn and the second yarn comprise atleast one of a multifilament yarn, a spun fiber yarn, a monofilamentyarn, or any combination thereof.
 12. The seamless insulation articleaccording to claim 1, further comprising at least one elastomeric yarn.13. The seamless insulation article according to claim 1, wherein thefirst yarn comprises a first shrinkage and the second yarn comprises asecond shrinkage being different from the first shrinkage to define adifferential relative shrinkage between the first yarn and the secondyarn when exposed to heat.
 14. The seamless insulation article accordingto claim 1, further comprising at least one smart yarn, said at leastone smart yarn comprising at least one of a ceramic, a syntheticmaterial, a phase change material, a biomimetric material, or anycombination thereof.
 15. The seamless insulation article according toclaim 1, further comprising at least one of a softener, an antimicrobialtreatment, a wicking treatment, a soil release treatment, a waterrepellent, an oil repellent, a fire retardant, or any combinationthereof.
 16. A method for making a seamless insulation article,comprising: combining a first yarn and a second yarn in a continuous webin a predetermined pattern; and finishing at least one surface of thecontinuous web to form a plurality of three-dimensional surfaces,wherein the plurality of three-dimensional surfaces define at least twodiscrete regions having different contrasting insulative capacityarranged in the predetermined pattern, said at least two discreteregions comprising a first discrete region and a second discrete region,and wherein the first discrete region comprises a first insulativecapacity, the second discrete region comprises a second insulativecapacity, and the second insulative capacity is greater than the firstinsulative capacity.
 17. The method according to claim 16, whereincombining a first yarn and a second yarn in a continuous web in apredetermined pattern comprises at least one of tubular circularknitting, plaiting, reverse plaiting, warp knitting, weaving, or anycombination thereof.
 18. The method according to claim 16, whereincombining a first yarn and a second yarn in a continuous web in apredetermined pattern further comprises incorporating at least one smartyarn into the continuous web, said at least one smart yarn comprising atleast one of a ceramic, a synthetic material, a phase change material, abiomimetric material, or any combination thereof.
 19. The methodaccording to claim 16, further comprising: designing the predeterminedpattern; laminating the seamless insulated article with a secondarticle; and removing the seamless insulated article from the continuousweb according to the predetermined pattern.
 20. The method according toclaim 19, wherein designing the predetermined pattern comprisesdesigning the predetermined pattern for use in at least one of a jacket,a shirt, a pair of pants, a pair of shorts, a glove, a mitt, a sock, ashoe, a shoe insert, a blanket, a mattress cover, a mattress ticking, orany combination thereof.